CN112837035A - Production activity guidance assistance and supervision system for external operation post of chemical device - Google Patents
Production activity guidance assistance and supervision system for external operation post of chemical device Download PDFInfo
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Abstract
The embodiment of the invention discloses a production activity guidance auxiliary and supervision system for an external operation post of a chemical device, which comprises: the wireless intelligent handheld terminal comprises a wireless intelligent handheld terminal and a server platform, wherein the server platform comprises 4 management modules for daily process inspection, daily equipment inspection and basic maintenance, process sampling and field operation activity supervision, and is further provided with a communication module, the communication module is used for realizing information data communication between the server platform and the handheld terminal and between the server platform and other management systems, a 5G network communication mode is adopted between the communication module and the handheld terminal, and an Ethernet communication mode is adopted between the communication module and other management systems. The system can guide the daily work of external operators (such as route inspection and inspection specific requirements, equipment basic maintenance task list and sampling); providing a specific task quantification standard, data communication summary analysis and abnormity judgment in an auxiliary manner, and performing closed-loop management after problem discovery; and (4) carrying out tracking analysis and supervision on the quantized data and the performance indexes after the daily work of the personnel at the external operating posts is standardized so as to realize the risk identification and the continuous improvement of the improvement effect of the production site of the chemical device.
Description
Technical Field
The invention relates to the technical field of chemical industry, in particular to a system and a method for guiding, assisting and supervising production activities of an external operation post of a chemical device.
Background
The daily production activities of the chemical engineering devices are mainly undertaken by two kinds of post personnel, one is that a DCS operator (internal operation) positioned in a central centralized Control room remotely controls equipment instruments positioned on a production site through a distributed Control system DCS (distributed Control System), so that safe and stable production is ensured; another category is that operators working on the production site (external operations) ensure stable production and safety of chemical plants also through a series of activities on site (such as inspection, basic equipment maintenance, sampling, emergency interventions, and corresponding operations on site following internal operating instructions, etc.).
With the improvement of the production automation degree of the chemical industry, more and more external operation posts are transferred to the internal operation posts in the central centralized control room in site operation. However, after the post requirements of the external operators are simplified, the method has few specific detailed working contents, requirements and operating standards except for responding internal operation instructions to perform field operation, periodic inspection and sampling and monitoring on-site high-risk operation. For example, inspection requires that field operators perform periodic field meter reading and manual recording of a small amount (generally less than 10% of the total) of process parameters on-site. The manual inspection recording mode is that a large amount of reports are missed due to limited coverage; secondly, when the timeliness and (and internal operation) interactivity are poor, problems occur, analysis, judgment and processing are not timely, and more serious results are caused; and thirdly, some problems discovered by inspection cannot be managed in a closed loop mode from a management process, and some problems which cannot cause adverse effects or influence in a short period of time can be finally developed and predicted to be more serious accident effects if the problems are not processed for a long time. These negative effects obviously result in the effect of the polling not being able to reach its intended purpose. Another main requirement of inspection is to find and warn equipment faults in advance, but only to subjectively judge the vibration and noise of key rotating equipment (pump or compressor) according to the self experience of external operation, and there is no specific standard for inspecting the measurement interval period and the over limit value.
The existence of the current production activities of the external operation posts can be found only from the two inspection cases: 1) the work of the post staff cannot be subjected to standardized management and supervision; 2) the workload and the effect of the device cannot be quantitatively measured; 3) and further, many hidden dangers of the chemical plant field cannot be found, reported and solved in time, and thus, an accident (unplanned parking, leakage of combustible substances and the like) or a potential serious process accident (fire, explosion and casualties) can be caused.
Disclosure of Invention
The technical problem to be solved by the embodiment of the invention is to provide a system and a method for guiding, assisting and monitoring the production activities of the external operation posts of the chemical device, wherein the system can guide the daily work of the external operation personnel (such as routing inspection and inspection specific requirements, equipment basic maintenance task list and sampling); providing a specific task quantification standard, data communication summary analysis and abnormity judgment in an auxiliary manner, and performing closed-loop management after problem discovery; and (4) carrying out tracking analysis and supervision on the quantized data and the performance indexes after the daily work of the personnel at the external operating posts is standardized so as to realize the risk identification and the continuous improvement of the improvement effect of the production site of the chemical device.
In order to solve the above technical problem, an embodiment of the present invention provides a guidance assistance and supervision system for production activities of an external operation post of a chemical apparatus, including:
wireless intelligent handheld terminal and server platform, the server platform including daily technology patrol and examine, daily equipment patrol and basic maintenance, technology sampling, 4 management modules of field operation activity supervision, still be equipped with communication module, communication module is used for realizing server platform and handheld terminal, other management systems include the DCS system, hidden danger investigation and management system, the information data UNICOM of Laboratory Information Management System (LIMS) and operation permission system (PTW) etc., adopt 5G network communication mode between communication module and the handheld terminal, communication module and other management systems adopt the ethernet communication mode.
Furthermore, the daily process polling module, the daily equipment polling and basic maintenance module and the process sampling module correspond to field operation points and comprise polling points, maintenance points and sampling points, each field operation point is provided with a two-dimensional code which can be identified by a handheld terminal, the handheld terminal can identify the two-dimensional code and read the working information or requirements of the field operation point from the two-dimensional code, the hand-held terminal can also input inspection measurement data, equipment maintenance and sampling information, 3 management modules on the server platform can set the standardized and quantized contents and requirements of the field work of the corresponding external operating posts, the server platform can generate a working list of each external operating post on duty according to the division of the responsibility area of the external operating post of each field operating point, the operation interval and the latest completion time recorded in the system, and an optimized inspection route is recommended according to the field distribution geographical position of the server platform.
Furthermore, the server platform can compare routing inspection measurement data input by the handheld terminal with DCS remote transmission measurement data to find faults or field input errors of the DCS or the field measurement instrument in advance; the server platform carries out a consistency comparison operation formula as follows:
(ABS (manual input value-DCS real time value))/manual input value 100%;
when the consistency of the polling measurement data and the DCS remote transmission measurement data is within an allowable range (the calculation result of the formula is less than or equal to +/-5%), the handheld terminal and the server platform mark that the work is finished; once the calculated value is +/-5%, displaying that the number of the inspection point is red in the handheld terminal, and buzzing (or vibrating) for a plurality of times to prompt an external operator to timely check the reason that the measured value of the DCS is inconsistent with the measured value on site and to communicate with the internal operator of the DCS for process abnormity; after the processing is finished, clicking 'reset' in the position number (two-dimensional code) polling display picture in the handheld terminal and inputting the current measured value again; if the field measurement value and the DCS remote transmission value are within the range (the calculation result of the formula is less than or equal to +/-5%), the red bit number is changed back to the normal font color, the inspection point is identified to be finished in an inspection list on the handheld terminal of the outside operating post staff, and the system stores the final input value and the input time of the inspection point again; if the problems found by the inspection point can not be solved in work (the condition that the outer operating post staff resets the inspection point corresponding to the handheld terminal is not met), the inspection point can be kept in a red state to be solved in the handheld terminal and the server platform, and when a new in-work inspection work list and an inspection route are generated after the next outer operating post staff receives work, the inspection point in the red state to be solved left in the previous work is placed at the first line of the work list and the first station of the inspection line; after the problem of the inspection point in the red state is solved, the staff at the off-duty operation post clicks the reset function of the handheld terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; if the problem of the red inspection point still cannot be solved in the second shift, filling remark information (the problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the inspection parameter display is changed from red to yellow and marked as 'hidden danger', the hidden danger can be transmitted to a hidden danger investigation and management system through a communication module of the server platform, a corresponding hidden danger finding entry is generated in the hidden danger finding entry, after the problem is finally solved, when the hidden danger investigation and management system closes the entry, the yellow state of the inspection parameter on the handheld terminal and the server platform is eliminated, the 'hidden danger' mark is cancelled, the inspection bit number is changed into an inputtable state again, and the inspection point can be reintroduced into a new round of arrangement plan of the inspection list.
Furthermore, the server platform can input data records through an external operator stored at each inspection point of the server platform to form a historical trend graph aiming at each process inspection point, and the data of each employee at the external operator station can be analyzed through analyzing the trends and the specific data to obtain the individual work performance KPI of the employee, and can also identify the promotion space and the improvement direction of the future stable and high-efficiency operation.
Further, the on-site operation supervision module acquires relevant information of all operation tickets of the current shift which have obtained approval permission from an operation permission PTW (permit to work) system by utilizing a communication module of the system and generates an operation list of the outside operation post responsible area; and when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld terminal of the staff at each off-shift operation position. When the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; once the outside operating post staff finds that the site operation has the phenomenon of non-compliance or danger, relevant violation or danger contents can be filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; until the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' can be reset to the normal state after the field inspection and confirmation; after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
Correspondingly, the invention provides an auxiliary method for guiding production activities of external operation posts of a chemical device, which is applied to the auxiliary and supervision system for guiding production activities of external operation posts of the chemical device provided by the embodiment of the invention and comprises the following steps:
step 1: the server platform is arranged, and the corresponding standardized and quantized contents and requirements of the field work of the external operation posts are respectively set in the four management modules in advance;
step 2: the handheld terminal receives the path information issued by the server and performs routing inspection, maintenance or sampling according to the information;
and step 3: the handheld terminal scans the two-dimension code of the field operation point to obtain work information or requirements, starts operation according to the information or the requirements, and records and uploads routing inspection measurement data, equipment maintenance or sampling information and the like in the handheld terminal after the operation is finished;
and 4, step 4: if the work in the step 3 is process inspection or daily equipment inspection and basic maintenance, the following steps are required: 4.1 if the consistency of the measurement data recorded in the step 3 and the DCS remote transmission measurement data is within the allowable range, the handheld terminal and the server platform can mark that the work is finished after the measurement data is uploaded; 4.2 if the consistency is not within the allowable range, analyzing and processing the problem in the handheld terminal according to the prompt, after the processing is finished, clicking 'reset' in the polling display picture of the position number (two-dimensional code) in the handheld terminal and inputting the current measured value again; 4.3 if the problem found by the inspection point in 4.2 can not be solved in working (the condition that the outer operating post staff resets the corresponding inspection point in the handheld terminal is not satisfied), the inspection point is kept in a red state to be solved in the handheld terminal and the server platform, and when a new working list and a new route of the inspection of working in working are generated after the next outer operating post staff is in working, the inspection point in the red open state left in the previous working is placed at the first line of the list and the first station of the inspection line; 4.4 after the problem of the inspection point in the red state is solved, the staff at the post of the off-duty operation clicks the reset function of the hand-held wireless terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; 4.5 if the problem of the inspection point in the red state can not be solved in the second class, filling remark information (problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the routing inspection parameter display is changed from red to yellow and marked as 'hidden danger', the hidden danger can be transmitted to a hidden danger troubleshooting and management system through a communication module of the server platform, and a corresponding hidden danger finding entry is generated in the hidden danger finding and management system. After the problem is finally solved, when the hidden danger inspection and treatment system closes the item, the states of the handheld equipment and the server platform about the inspection parameters are eliminated from yellow states, the hidden danger mark is canceled, the inspection bit number is changed into an inputtable state again, and the inspection point is reintroduced into a new round of arrangement plan of the inspection list;
and 5: if the work in step 3 is process sampling, the following steps are required: 5.1 the server platform stores the received sampling information data; the process sampling module exchanges data Information with an LIMS (laboratory Information Management System) through a communication module of the System to send newly obtained sample Information to the LIMS, and the LIMS can generate new corresponding sample analysis requirements in the System; 5.2 temporarily adding sample analysis requirements by a production team or additionally adding certain analysis item requirements for the existing sample analysis project, directly sending the analysis requirements to the LIMS system through a communication module of the system, and simultaneously directly pushing the work to a handheld terminal corresponding to an external operation post by using a 5G wireless signal;
step 6: the process parameters input by the external operator in the inspection process each time are recorded and stored in the inspection point position numbers corresponding to the server platform, after a period of time is accumulated, a historical trend record aiming at each process inspection point can be formed, and the promotion space and direction of the future stable operation of the control parameters are obtained through the analysis of the trend; KPI indexes such as inspection completion rate or inspection abnormal quantity of each inspection worker can be analyzed to obtain different conclusions of the working efficiency and effect of the external operation; and improving the overall level of the personnel in the outer operating posts through further standardization and training according to the conclusion.
Correspondingly, the invention also provides a method for supervising the production activities of the external operation posts of the chemical device, which is applied to the guidance assistance and supervision system for the production activities of the external operation posts of the chemical device provided by the embodiment of the invention and comprises the following steps:
step 1: the field operation supervision module acquires relevant information of all operation tickets of the current shift which are approved from an operation permission PTW (permit to work) system by utilizing a communication module of the system and generates an operation list of an area in charge of the external operation position;
step 2: when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld wireless intelligent terminal of the staff at each off-shift operation position; when the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; specifically, once an external operating post employee finds that the field operation has the phenomenon of non-compliance or danger, relevant violation or danger contents are filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; when the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' is reset to the normal state after the on-site inspection and confirmation;
and step 3: after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
The invention has the beneficial effects that:
(1) the system is provided with four management modules of daily process inspection, daily equipment inspection and basic maintenance, process sampling and field operation activity supervision, and almost all the contents of daily work of an external operation post of the chemical device are contained, so that the full coverage of the daily work management of the staff at the external operation post is realized, various daily production activities carried out on the site of the staff are standardized, and the specific work contents of the staff are subjected to auxiliary guidance;
(2) the wireless intelligent handheld terminal used by staff in an external operating post on site and each management module in a server platform are exchanged by using a 5G wireless communication technology, and also exchanged with other system information through the server platform, and a process inspection module and an equipment inspection and basic maintenance module in the server platform acquire related data of a DCS through a communication module, so that related information communication load between the external operating post and an internal operating post in charge of DCS operation is reduced, and the communication efficiency between the external operating post and the internal operating post in abnormal working conditions is improved;
(3) the standardization and quantification of the work of the external operation posts of the chemical engineering device are realized by utilizing the advanced input setting of the work content, the requirements and the flow in each module of the server platform;
(4) the communication module in the server platform is communicated with the information of the DCS system, the hidden danger troubleshooting and management system, the LIMS system and the PTW system, so that the automatic high-efficiency processing of the external operating post in the links of generating a work list on duty, judging problems found in field work, confirming the tracking and handling after the problems and the like is realized, and meanwhile, the closed-loop management of various problems which can be solved for a long time and are found by the external operating post polling is realized by exchanging information and data between the communication module arranged on the server platform and the hidden danger troubleshooting and management system;
(5) the system stores various data and records of the field activities of the external operation posts in an electronic form on the server platform, so that a basis is provided for long-term tracking and analysis of optimization of production parameters and equipment stability of related process equipment, and a basis is also provided for tracking and improving the work performance of the external operation posts, and the identification and improvement effects of the field risks of the chemical engineering devices are improved;
(6) the process sampling module and the field operation supervision module in the system server platform are interconnected with the LIMS of an analysis room and the PTW system of an operation team by utilizing the communication module, so that the daily main work of the two external operation post employees of process sampling and field operation supervision is brought into one system for management, the integration of all the daily work of the external operation post employees in the production of a chemical device is basically realized through one handheld terminal, and the closed loop on standardization, quantification and management is realized.
Drawings
Fig. 1 is a schematic structural diagram of an embodiment of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application can be combined with each other without conflict, and the present invention is further described in detail with reference to the drawings and specific embodiments.
If directional indications (such as up, down, left, right, front, and rear … …) are provided in the embodiment of the present invention, the directional indications are only used to explain the relative position relationship between the components, the movement, etc. in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indications are changed accordingly.
In addition, the descriptions related to "first", "second", etc. in the present invention are only used for descriptive purposes and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature.
Referring to fig. 1, the system for guiding, assisting and monitoring the production activities of the external operation post of the chemical plant according to the embodiment of the present invention includes:
wireless intelligent handheld terminal and server platform, the server platform including daily technology patrol and examine, daily equipment patrol and basic maintenance, technology sampling, 4 management modules of field operation activity supervision, still be equipped with communication module, communication module is used for realizing server platform and handheld terminal, other management systems include the DCS system, hidden danger investigation and management system, the information data UNICOM of Laboratory Information Management System (LIMS) and operation permission system (PTW) etc., adopt 5G network communication mode between communication module and the handheld terminal, communication module and other management systems adopt the ethernet communication mode.
As an implementation mode, the daily process inspection module, the daily equipment inspection and basic maintenance module and the process sampling module correspond to field operation points and comprise inspection points, maintenance points and sampling points, each field operation point is provided with a two-dimensional code which can be identified by a handheld terminal, the handheld terminal can identify the two-dimensional code and read the working information or requirements of the field operation point from the two-dimensional code, the hand-held terminal can also input inspection measurement data, equipment maintenance and sampling information, 3 management modules on the server platform can set the standardized and quantized contents and requirements of the field work of the corresponding external operating posts, the server platform can generate a working list of each external operating post on duty according to the division of the responsibility area of the external operating post of each field operating point, the operation interval and the latest completion time recorded in the system, and an optimized inspection route is recommended according to the field distribution geographical position of the server platform.
As an implementation mode, the server platform can compare routing inspection measurement data input by the handheld terminal with DCS remote transmission measurement data to find faults or field input errors of the DCS or the field measurement instrument in advance; the server platform carries out a consistency comparison operation formula as follows:
(ABS (manual input value-DCS real time value))/manual input value 100%;
when the consistency of the polling measurement data and the DCS remote transmission measurement data is within an allowable range (the calculation result of the formula is less than or equal to +/-5%), the handheld terminal and the server platform mark that the work is finished; once the calculated value is +/-5%, displaying that the number of the inspection point is red in the handheld terminal, and buzzing (or vibrating) for a plurality of times to prompt an external operator to timely check the reason that the measured value of the DCS is inconsistent with the measured value on site and to communicate with the internal operator of the DCS for process abnormity; after the processing is finished, clicking 'reset' in the position number (two-dimensional code) polling display picture in the handheld terminal and inputting the current measured value again; if the field measurement value and the DCS remote transmission value are within the range (the calculation result of the formula is less than or equal to +/-5%), the red bit number is changed back to the normal font color, the inspection point is identified to be finished in an inspection list on the handheld terminal of the outside operating post staff, and the system stores the final input value and the input time of the inspection point again; if the problems found by the inspection point can not be solved in work (the condition that the outer operating post staff resets the inspection point corresponding to the handheld terminal is not met), the inspection point can be kept in a red state to be solved in the handheld terminal and the server platform, and when a new in-work inspection work list and an inspection route are generated after the next outer operating post staff receives work, the inspection point in the red state to be solved left in the previous work is placed at the first line of the work list and the first station of the inspection line; after the problem of the inspection point in the red state is solved, the staff at the off-duty operation post clicks the reset function of the handheld terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; if the problem of the red inspection point still cannot be solved in the second shift, filling remark information (the problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the inspection parameter display is changed from red to yellow and marked as 'hidden danger', the hidden danger can be transmitted to a hidden danger investigation and management system through a communication module of the server platform, a corresponding hidden danger finding entry is generated in the hidden danger finding entry, after the problem is finally solved, when the hidden danger investigation and management system closes the entry, the yellow state of the inspection parameter on the handheld terminal and the server platform is eliminated, the 'hidden danger' mark is cancelled, the inspection bit number is changed into an inputtable state again, and the inspection point can be reintroduced into a new round of arrangement plan of the inspection list.
As an implementation manner, the server platform may form a historical trend graph for each process patrol point by inputting data records by an external operator at each patrol point stored in the server platform, and may analyze data of each employee at the external operator station by analyzing the trends and specific data to obtain a personal performance KPI, and may also identify a promotion space and an improvement direction for future stable and efficient operation.
In one embodiment, the on-site operation supervision module acquires the relevant information of all the operation tickets of the current shift which have been approved from the operation permission ptw (permit to work) system by using the communication module of the system and generates the operation list of the outside operation position responsible area; and when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld terminal of the staff at each off-shift operation position. When the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; once the outside operating post staff finds that the site operation has the phenomenon of non-compliance or danger, relevant violation or danger contents can be filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; until the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' can be reset to the normal state after the field inspection and confirmation; after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
Correspondingly, the invention provides an auxiliary method for guiding production activities of external operation posts of a chemical device, which is applied to the auxiliary and supervision system for guiding production activities of external operation posts of the chemical device provided by the embodiment of the invention and comprises the following steps:
step 1: the server platform is arranged, and the corresponding standardized and quantized contents and requirements of the field work of the external operation posts are respectively set in the four management modules in advance;
step 2: the handheld terminal receives the path information issued by the server and performs routing inspection, maintenance or sampling according to the information;
and step 3: the handheld terminal scans the two-dimension code of the field operation point to obtain work information or requirements, starts operation according to the information or the requirements, and records and uploads routing inspection measurement data, equipment maintenance or sampling information and the like in the handheld terminal after the operation is finished;
and 4, step 4: if the work in the step 3 is process inspection or daily equipment inspection and basic maintenance, the following steps are required: 4.1 if the consistency of the measurement data recorded in the step 3 and the DCS remote transmission measurement data is within the allowable range, the handheld terminal and the server platform can mark that the work is finished after the measurement data is uploaded; 4.2 if the consistency is not within the allowable range, analyzing and processing the problem in the handheld terminal according to the prompt, after the processing is finished, clicking 'reset' in the polling display picture of the position number (two-dimensional code) in the handheld terminal and inputting the current measured value again; 4.3 if the problem found by the inspection point in 4.2 can not be solved in working (the condition that the outer operating post staff resets the corresponding inspection point in the handheld terminal is not satisfied), the inspection point is kept in a red state to be solved in the handheld terminal and the server platform, and when a new working list and a new route of the inspection of working in working are generated after the next outer operating post staff is in working, the inspection point in the red open state left in the previous working is placed at the first line of the list and the first station of the inspection line; 4.4 after the problem of the inspection point in the red state is solved, the staff at the post of the off-duty operation clicks the reset function of the hand-held wireless terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; 4.5 if the problem of the inspection point in the red state can not be solved in the second class, filling remark information (problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the routing inspection parameter display is changed from red to yellow and marked as 'hidden danger', the hidden danger can be transmitted to a hidden danger troubleshooting and management system through a communication module of the server platform, and a corresponding hidden danger finding entry is generated in the hidden danger finding and management system. After the problem is finally solved, when the hidden danger inspection and treatment system closes the item, the states of the handheld equipment and the server platform about the inspection parameters are eliminated from yellow states, the hidden danger mark is canceled, the inspection bit number is changed into an inputtable state again, and the inspection point is reintroduced into a new round of arrangement plan of the inspection list;
and 5: if the work in step 3 is process sampling, the following steps are required: 5.1 the server platform stores the received sampling information data; the process sampling module exchanges data Information with an LIMS (laboratory Information Management System) through a communication module of the System to send newly obtained sample Information to the LIMS, and the LIMS can generate new corresponding sample analysis requirements in the System; 5.2 temporarily adding sample analysis requirements by a production team or additionally adding certain analysis item requirements for the existing sample analysis project, directly sending the analysis requirements to the LIMS system through a communication module of the system, and simultaneously directly pushing the work to a handheld terminal corresponding to an external operation post by using a 5G wireless signal;
step 6: the process parameters input by the external operator in the inspection process each time are recorded and stored in the inspection point position numbers corresponding to the server platform, after a period of time is accumulated, a historical trend record aiming at each process inspection point can be formed, and the promotion space and direction of the future stable operation of the control parameters are obtained through the analysis of the trend; KPI indexes such as inspection completion rate or inspection abnormal quantity of each inspection worker can be analyzed to obtain different conclusions of the working efficiency and effect of the external operation; and improving the overall level of the personnel in the outer operating posts through further standardization and training according to the conclusion.
Correspondingly, the invention also provides a method for supervising the production activities of the external operation posts of the chemical device, which is applied to the guidance assistance and supervision system for the production activities of the external operation posts of the chemical device provided by the embodiment of the invention and comprises the following steps:
step 1: the field operation supervision module acquires relevant information of all operation tickets of the current shift which are approved from an operation permission PTW (permit to work) system by utilizing a communication module of the system and generates an operation list of an area in charge of the external operation position;
step 2: when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld wireless intelligent terminal of the staff at each off-shift operation position; when the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; specifically, once an external operating post employee finds that the field operation has the phenomenon of non-compliance or danger, relevant violation or danger contents are filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; when the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' is reset to the normal state after the on-site inspection and confirmation;
and step 3: after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
The invention has the beneficial effects that:
(1) the system is provided with four management modules of daily process inspection, daily equipment inspection and basic maintenance, process sampling and field operation activity supervision, and almost all the contents of daily work of an external operation post of the chemical device are contained, so that the full coverage of the daily work management of the staff at the external operation post is realized, various daily production activities carried out on the site of the staff are standardized, and the specific work contents of the staff are subjected to auxiliary guidance;
(2) the wireless intelligent handheld terminal used by staff in an external operating post on site and each management module in a server platform are exchanged by using a 5G wireless communication technology, and also exchanged with other system information through the server platform, and a process inspection module and an equipment inspection and basic maintenance module in the server platform acquire related data of a DCS through a communication module, so that related information communication load between the external operating post and an internal operating post in charge of DCS operation is reduced, and the communication efficiency between the external operating post and the internal operating post in abnormal working conditions is improved;
(3) the standardization and quantification of the work of the external operation posts of the chemical engineering device are realized by utilizing the advanced input setting of the work content, the requirements and the flow in each module of the server platform;
(4) the communication module in the server platform is communicated with the information of the DCS system, the hidden danger troubleshooting and management system, the LIMS system and the PTW system, so that the automatic high-efficiency processing of the external operating post in the links of generating a work list on duty, judging problems found in field work, confirming the tracking and handling after the problems and the like is realized, and meanwhile, the closed-loop management of various problems which can be solved for a long time and are found by the external operating post polling is realized by exchanging information and data between the communication module arranged on the server platform and the hidden danger troubleshooting and management system;
(5) the system stores various data and records of the field activities of the external operation posts in an electronic form on the server platform, so that a basis is provided for long-term tracking and analysis of optimization of production parameters and equipment stability of relevant process equipment, and a basis is also provided for tracking and improving the work performance of the external operation posts, and the identification and improvement effects of the field risks of the chemical engineering devices are improved.
(6) The process sampling module and the field operation supervision module in the system server platform are interconnected with the LIMS of an analysis room and the PTW system of an operation team by utilizing the communication module, so that the daily main work of the two external operation post employees of process sampling and field operation supervision is brought into one system for management, the integration of all the daily work of the external operation post employees in the production of a chemical device is basically realized through one handheld terminal, and the closed loop on standardization, quantification and management is realized.
Example 1: the routine process inspection of an external operating station is taken as an example:
the server platform is arranged (daily process inspection module):
setting up a process measurement parameter list of all daily patrols, wherein the data parameters of each measurement point comprise:
1) a description of the measurement point (e.g., a level gauge of the tank 123), a location number (e.g., 123 LG-001), and a corresponding two-dimensional code; (ii) a
2) Patrol measurement interval time (e.g., 3 hours);
3) an external station (e.g., polymerization plant section one) that performs the inspection;
4) corresponding remote transmission measuring point position numbers aiming at the same parameter in the DCS and a real-time value (if the remote transmission measuring point position numbers exist, for example, a DCS remote transmission liquid level meter 123LIA-002 of the storage tank 123) obtained from the DCS;
5) production operating upper limit (e.g., 95% if any);
6) lower limit of production operation (e.g., 20% if any).
When each production operation shift is handed over, the server platform generates a process inspection list (including the instrument position number and the deadline time of an inspection measurement point) of the current shift according to the measurement list and the inspection interval time in the step one, and generates an optimized inspection route and inspection points (the inspection route actually considers the comprehensive optimized inspection route after three activities of daily process inspection, daily equipment inspection, basic maintenance and sampling) according to the field position and the inspection interval time of each inspection point and pushes the optimized inspection route and the optimized inspection points to the handheld wireless intelligent terminal of staff at each external operation position of the current shift;
and (III) carrying out daily process polling on the spot by the staff in the external operating post according to the polling list in the step (II). And scanning the two-dimensional code of the corresponding inspection point on the site by using a handheld device at the specified inspection point, and then inputting the process parameter data obtained by site measurement. The data is transmitted back to the server platform via wireless 5G.
And (IV) the server platform stores the received input data and the input time information and compares the input data and the input time information with a set upper limit value or/and a set lower limit value respectively. Once the abnormal process exceeds the preset threshold value, the position number is displayed to be red in the handheld terminal, buzzing (or vibration) is sent for a plurality of times, and the external operation is prompted to timely check the possible reasons of the abnormal process on site and communicate with the DCS internal operation to process the abnormal process.
If the DCS system also has remote measurement real-time data aiming at the routing inspection parameters, comparison operation is carried out on the server platform, and the formula is as follows: (ABS (Manual input value-DCS real-time value))/Manual input value 100%
Once the calculated value is +/-5%, the bit number is displayed to be red in the handheld terminal, and buzzing (or vibration) is sent for a plurality of times, so that the reason that the DCS measured value is inconsistent with the field measured value is prompted to be checked in time by external operation on site.
And (V) if the personnel in the external operation post solve the problems found by the polling, clicking 'reset' in the polling display picture of the position number (two-dimensional code) in the handheld terminal and re-inputting the current measured value. The measurement value is within range and the red bit number is changed back to the normal font color (e.g., black). If the process patrol inspection parameters which are displayed in red are not processed and finished when the work on duty on the day is finished at the external operation post, one of the following two operations is executed in the handheld terminal:
1) in the short term (next team), the process inspection measurement position number with the red font is preferentially displayed (at the top of the route of the normal inspection list) in the handheld terminal of the personnel at the outer operating post corresponding to the next team, and the process inspection measurement position number is brought into the inspection push list and the route of the outer operating post. After the personnel at the external operating post work solves the problems found by the patrol, the personnel clicks 'reset' in the patrol display picture of the position number (two-dimensional code) in the handheld terminal and inputs the measured value at the moment again. The measurement value is within range and the red bit number is changed back to the normal font color (e.g., black).
2) The process inspection parameters which cannot be solved in a short period and have acceptable risks (such as 98% fault display of a field magnetic turning plate liquid level meter and 95% exceeding of an operation upper limit value) are filled with remark information, namely 'the measuring instrument is required to be maintained when the fault occurs', and then 'the remark information is selected as a hidden trouble inspection finding item'. At this point, the patrol parameter display changes from red to yellow and is marked as "hidden danger". The position number and the remark information generate corresponding hidden danger registration contents in the hidden danger checking and managing system through a communication module of the system. Once the state of the item in the hidden trouble investigation and management system is changed to be 'off' by a hidden trouble management related responsible person, the system communication module obtains the state change of the item, the state of the routing inspection parameter on the handheld terminal and the server platform is changed from yellow to a normal color, the 'hidden trouble' mark is cancelled, the routing inspection position number restarts the countdown of the routing inspection interval, and the polling interval is re-included in the routing inspection list and route of the outer operating position of the current shift in (two) when the countdown is finished.
And (VI) long-term data tracking and KPI trend analysis of the server platform:
and storing the process measurement data records input by inspection in the inspection point numbers corresponding to the server platform, accumulating for a period of time, forming historical trend records aiming at each process inspection point, and obtaining the promotion space and direction of the future stable operation of the control parameter by analyzing the trend.
And KPI indexes such as inspection completion rate or abnormal quantity found by inspection of each inspection worker can be analyzed to obtain different conclusions of the working efficiency and effect of the external operation. And improving the overall level of the personnel in the outer operating posts through further standardization and training according to the conclusion.
Example 2: daily equipment inspection and basic maintenance of other operating posts
The server platform is arranged (a daily standby inspection and basic maintenance module):
setting up all equipment operation measurement parameter lists which need to be subjected to daily inspection, wherein the due data parameters of each measurement point comprise:
1) a description of the measurement point (e.g., vibration of the pump 111), a bit number (e.g., p111. vg), and a corresponding two-dimensional code;
2) patrol measurement interval time (e.g., 72 hours);
3) an external station (e.g., polymerization plant section one) that performs the inspection;
4) corresponding remote transmission measuring point bit numbers aiming at the same parameter in the DCS and real-time values obtained from the DCS (if the remote transmission measuring point bit numbers exist, such as DCS remote transmission vibration measurement P111.VI of a pump P111);
5) upper limit of plant operation (e.g., 100um if any);
6) lower limit of plant operation (if any);
or setting all the basic maintenance lists of the equipment which needs to be subjected to the regular basic maintenance, wherein each basic maintenance operation setting page comprises:
equipment location number (e.g., pump P111), basic maintenance work content (oil change), and corresponding two-dimensional code;
basic maintenance interval (e.g., 6 months)
Settings to trigger basic maintenance of the equipment (if any, e.g. P111.VI > 100 um)
When each production operation shift is handed over, the server platform generates a current process inspection list (including the position number and the deadline time of an inspection measuring point) according to the equipment operation measuring list, the equipment basic maintenance list and the inspection interval time in the step (I), generates an optimized inspection route and an optimized inspection point (the inspection route actually considers the comprehensive optimized inspection route after three activities of daily process inspection, daily equipment inspection, basic maintenance and sampling) according to the field position and the inspection interval time of each inspection point, and pushes the optimized inspection route and the optimized inspection point to the handheld wireless intelligent terminal of each external operation position staff in the current shift; if some plant maintenance activities do not reach the set interval, but because of the set value that triggers the plant maintenance (e.g., the shaft vibration value of a certain pump is higher than 100 um), the plant maintenance will also be included in the overall routing inspection routes of the outside operator staff of the current day or next team.
And (III) performing routine equipment inspection and basic maintenance on the spot by the staff of the external operation post according to the inspection list in the step (I). And scanning the two-dimensional code of the corresponding inspection point on the spot by using the handheld device at the specified inspection point, and then inputting the equipment operation data obtained by field measurement. The data is transmitted back to the server platform via wireless 5G.
And (IV) the server platform stores the received equipment data and compares the equipment data with a set upper limit value or/and a set lower limit value of the equipment operation respectively. Once the abnormal communication exceeds the preset value, the position number is displayed in the handheld terminal to be red, buzzing (or vibrating) is sent for a plurality of times, and the possible reasons of abnormal occurrence are prompted to be checked on site by an external operation and the communication processing of equipment abnormality is carried out with the DCS internal operation.
If the DCS system also has remote measurement real-time data aiming at the routing inspection parameters, comparison operation is carried out on the server platform, and the formula is as follows: (ABS (Manual input value-DCS real-time value))/Manual input value 100%
Once the calculated value is +/-5%, the bit number is displayed to be red in the handheld terminal, and buzzing (or vibration) is sent for a plurality of times, so that the reason that the DCS measured value is inconsistent with the field measured value is prompted to be checked in time by external operation on site.
And (V) if the personnel in the external operation post solve the problems found by the polling, clicking 'reset' in the polling display picture of the position number (two-dimensional code) in the handheld terminal and re-inputting the current measured value. The measurement value is within range and the red bit number is changed back to the normal font color (e.g., black). If the process patrol inspection parameters which are displayed in red are not processed and finished when the work on duty on the day is finished at the external operation post, one of the following two operations is executed in the handheld terminal:
1) in the short term (next team), the problem that can be solved, then in the handheld terminal of the outer post personnel of operating that next team corresponds, the equipment that will look round of red typeface is patrolled and is measured the position number and is shown with priority (in the top of normally patrolling and examining the list route), and incorporates into this outer post and patrols and examines in propelling movement list and route. After the personnel at the external operating post work solves the problems found by the patrol, the personnel clicks 'reset' in the patrol display picture of the position number (two-dimensional code) in the handheld terminal and inputs the measured value at the moment again. The measurement value is within range and the red bit number is changed back to the normal font color (e.g., black).
2) If the equipment operation inspection parameters (such as the vibration of a field pump P111, exceeding the upper limit value of 100 um) which cannot be solved in a short period and have acceptable risks are detected, the red inspection parameter display card in the handheld equipment is filled with remark information 'lack of spare parts for maintenance, replacement of machine seals in the first time when the spare parts are in place', and 'serving as a hidden danger troubleshooting discovery item' is selected. At this point, the patrol parameter display changes from red to yellow and is marked as "hidden danger". The position number and the remark information generate corresponding hidden danger registration contents in the hidden danger checking and managing system through a communication module of the system. Once the state of the item in the hidden trouble investigation and management system is changed to be 'closed' by the hidden trouble management-related responsible person, after the state change of the item is acquired through the system communication module, the state of the routing inspection parameter on the handheld terminal and the server platform is changed from yellow to green, the 'hidden trouble' mark is cancelled, the routing inspection position number restarts the countdown of the routing inspection interval, and the polling list and route of the outer operating position of the current shift are re-included in (two) when the countdown is finished.
And (VI) after the external operation post finishes the basic maintenance work of the equipment required by the inspection list, checking the basic maintenance items of the equipment and finishing the basic maintenance items. The completion time and completion item are transmitted back to the server platform via the 5G signal of the handheld terminal and stored. And meanwhile, according to the interval time setting of the basic maintenance of the equipment, a timer of the basic maintenance work of the equipment in the next round starts to time and is included into the equipment inspection and basic maintenance list of the off-duty operation post in the current shift in step (II) when the time is about to expire.
And (seventhly), long-term data tracking and KPI trend analysis of the server platform:
the device measurement data records of the inspection input are stored in the inspection point numbers corresponding to the server platform, after a period of time is accumulated, historical trend records aiming at each device inspection point can be formed, and future device reliability promotion space and direction of the parameters are obtained through analysis of the trends.
And KPI indexes such as inspection completion rate or abnormal quantity found by inspection of each inspection worker can be analyzed to obtain different conclusions of the working efficiency and effect of the external operation. And improving the overall level of the personnel in the outer operating posts through further standardization and training according to the conclusion.
Example 3: taking the sampling of the outer operating station as an example
The server platform is arranged (a process sampling module):
setting a list of all sampling points to be sampled, wherein the due data parameters of each sampling point comprise:
1) a description of the sample point (e.g., a sample point for a storage tank 123 inlet pipeline product), a bit number (e.g., SC 12301), and a corresponding two-dimensional code;
2) sampling interval time (e.g., 8 hours);
3) an external station (e.g., polymerization plant section one) that performs the sampling;
4) the size of the sampling container (e.g., a 50ml glass sampling bottle);
when each production operation shift is handed over, the server platform generates a sampling list of the current shift (including the bit number of a sampling point, the specification of a sampling bottle and the deadline time) according to the sampling list and the sampling interval time in the step one, and generates an optimized routing inspection/sampling route (the routing inspection route actually considers the comprehensive optimized routing inspection routes of three activities of daily process routing inspection, daily equipment routing inspection, basic maintenance and sampling) according to the field position and the interval time of each sampling point and pushes the routing inspection/sampling route to the handheld wireless intelligent terminal of the staff at each off-shift operation position in the current shift;
and (III) performing daily sampling work on site by the staff in the external operation post according to the inspection/sampling list in the step (II). And scanning the two-dimensional code of the corresponding sampling point on site at the specified sampling point by using a handheld device, and acquiring sampling information (such as which sampling container and sampling amount are used) of the sampling point. After the sampling work is finished, the number of the sample is input on the page of the handheld terminal corresponding to the sampling bit number/two-dimensional code according to the sampling operation rule, and once the input is finished and confirmed, the data of the sample information (the number and the sampling time) is immediately transmitted back to the server platform through the wireless 5G.
And (IV) the server platform stores the received sampling information data. Meanwhile, the sampling module exchanges data Information with an LIMS (laboratory Information Management System) through a communication module of the System to send the newly obtained sample Information to the LIMS, the LIMS generates a corresponding sample analysis request entry in the System, and the analysis result is stored in the entry disciplinedly after the analysis and assay center completes index analysis on the sample.
And (V) when the reason analysis is carried out for some reasons (such as product quality fluctuation), the sampling frequency of a certain sampling point needs to be increased outside the daily sampling activity. The operating team can directly generate new sampling requirements and requirements in the sampling module of the server platform without having to communicate with the analytical testing center to sample and add sampling requirements in the LIMS system as before.
Example 4: site operation supervision of other operating stations as an example
Server platform setup (field operation supervision module):
the on-site operation supervision module utilizes a communication module of the system to acquire relevant information of all operation tickets of the current shift which have been approved from an operation permission PTW (permit to work) system and generates an operation list of the responsible area of the external operation position. The acquiring, by the field operation supervision module, the operation information from the PTW includes:
work place (e.g. polymerization workshop section-storage tank 123 cofferdam inner area)
Work content (for example, maintenance of damaged insulation layer of storage tank 123)
Job execution team (contractor XX construction team)
Operation risk and management and control measures (for example, a scaffold is required to be erected for high-altitude operation, and the risk of falling from high altitude exists, the management and control measures are that the scaffold can be used after being checked and approved, and meanwhile, constructors must wear safety ropes for operation)
Secondly, when each production operation shift is handed over, the server platform pushes the production operation shift to the handheld wireless intelligent terminal of the staff at each off-shift operation position according to the operation list in the step one;
and (III) when the external operation post staff is on the spot, the operation activities which are carried out on the spot can be checked and supervised in a targeted way according to the spot operation information pushed by the handheld terminal platform (for example, whether the spot operation content is consistent with the application operation content, whether each management and control measure of the spot operation is ensured according to the operation permission application content, and the like).
And (IV) once the outside operator staff find that the site operation has the phenomenon of non-compliance or danger, filling related violation or danger contents into the operation page of the handheld terminal equipment. For the immediate correction and modification, the operation is continued after the operation is required to be immediately modified; and stopping the field work for the work which cannot be immediately corrected, and adjusting the work state to be a 'shutdown correction' yellow state at the handheld terminal. And resetting the 'shutdown rectification' yellow state to a normal state after the field constructor informs the external operation post staff of completing the rectification content and confirming the 'shutdown rectification' yellow state through field inspection.
And (V) after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points. For example, the total number of the shutdown operations is counted, and then the operation location, the operation content, the operation implementation team and the operation risk are used for classification, so as to find out the data with the previous shutdown operations. For example, the work content including high-altitude work is stopped for the most times, and the reason for stopping is that the safety rope is not tied normally, so that the operation content including high-altitude work can be regarded as the key point of the next field work modification. The training and inspection of constructors can be more targeted. If the number of times of the downtime of the XX construction team is the largest, the supervision of the operation site which is carried out by the XX construction team can be strengthened, and even the entrance construction qualification of the XX construction team can be cancelled from the contractor management system. .
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. The utility model provides a supplementary and monitored control system is guided in post production activity of operating outside chemical plant, its characterized in that includes: wireless intelligent handheld terminal and server platform, the server platform including daily technology patrol and examine, daily equipment patrol and basic maintenance, technology sampling, 4 management modules of field operation activity supervision, still be equipped with communication module, communication module is used for realizing server platform and handheld terminal, other management systems include the DCS system, hidden danger investigation and management system, the information data UNICOM of Laboratory Information Management System (LIMS) and operation permission system (PTW) etc., adopt 5G network communication mode between communication module and the handheld terminal, communication module and other management systems adopt the ethernet communication mode.
2. The system as claimed in claim 1, wherein the daily process inspection module, the daily equipment inspection and basic maintenance module, and the process sampling module correspond to field operation points, and include inspection points, maintenance points, and sampling points, each field operation point is provided with a two-dimensional code recognizable by the handheld terminal, the handheld terminal can recognize the two-dimensional code and read the working information or requirement of the field operation point, the handheld terminal can also input inspection measurement data, equipment maintenance and sampling information, the 3 management modules on the server platform can set the standardized and quantized contents and requirements of the field work of the corresponding external operation post, the server platform can generate the working list of the external operation post according to the division of the external operation post area of each field operation point, the operation interval, and the last operation completion time recorded in the system, and an optimized routing inspection route is recommended according to the site distribution geographical position of the routing inspection system.
3. The chemical plant external operation post production activity guidance assistance and supervision system according to claim 1, wherein the server platform can find out faults or field input errors of the DCS or field measuring instrument in advance by comparing patrol measuring data entered by the hand-held terminal with DCS remote transmitting measuring data; the server platform carries out a consistency comparison operation formula as follows:
(ABS (manual input value-DCS real time value))/manual input value 100%;
when the consistency of the polling measurement data and the DCS remote transmission measurement data is within an allowable range (the calculation result of the formula is less than or equal to +/-5%), the handheld terminal and the server platform mark that the work is finished; once the calculated value is +/-5%, displaying that the number of the inspection point is red in the handheld terminal, and buzzing (or vibrating) for a plurality of times to prompt an external operator to timely check the reason that the measured value of the DCS is inconsistent with the measured value on site and to communicate with the internal operator of the DCS for process abnormity; after the processing is finished, clicking 'reset' in the position number (two-dimensional code) polling display picture in the handheld terminal and inputting the current measured value again; if the field measurement value and the DCS remote transmission value are within the range (the calculation result of the formula is less than or equal to +/-5%), the red bit number is changed back to the normal font color, the inspection point is identified to be finished in an inspection list on the handheld terminal of the outside operating post staff, and the system stores the final input value and the input time of the inspection point again; if the problems found by the inspection point can not be solved in work (the condition that the outer operating post staff resets the inspection point corresponding to the handheld terminal is not met), the inspection point can be kept in a red state to be solved in the handheld terminal and the server platform, and when a new in-work inspection work list and an inspection route are generated after the next outer operating post staff receives work, the inspection point in the red state to be solved left in the previous work is placed at the first line of the work list and the first station of the inspection line; after the problem of the inspection point in the red state is solved, the staff at the off-duty operation post clicks the reset function of the handheld terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; if the problem of the red inspection point still cannot be solved in the second shift, filling remark information (the problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the inspection parameter display is changed from red to yellow and marked as 'hidden danger', the hidden danger can be transmitted to a hidden danger investigation and management system through a communication module of the server platform, a corresponding hidden danger finding entry is generated in the hidden danger finding entry, after the problem is finally solved, when the hidden danger investigation and management system closes the entry, the yellow state of the inspection parameter on the handheld terminal and the server platform is eliminated, the 'hidden danger' mark is cancelled, the inspection bit number is changed into an inputtable state again, and the inspection point can be reintroduced into a new round of arrangement plan of the inspection list.
4. The system as claimed in claim 1, wherein the server platform is configured to form a historical trend graph for each process inspection point by inputting data records from the outside operator at each inspection point of the server platform, and by analyzing the historical trend graph and specific data, the data of each employee at each inspection point can be analyzed to obtain the KPI of the personal performance of the employee, and the promotion space and improvement direction of future stable and efficient operations can be identified.
5. The system as claimed in claim 1, wherein the on-site operation supervision module uses the communication module of the system to obtain the relevant information of all the operation tickets of the current shift that have been approved from the operation permission ptw (permit to work) system and generate the operation list of the responsible area of the off-site operation; when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld terminal of the staff at each off-shift operation position; when the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; once the outside operating post staff finds that the site operation has the phenomenon of non-compliance or danger, relevant violation or danger contents can be filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; until the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' can be reset to the normal state after the field inspection and confirmation; after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
6. A chemical plant external operation post production activity guidance auxiliary method is characterized by comprising the following steps:
step 1: the server platform is arranged, and the corresponding standardized and quantized contents and requirements of the field work of the external operation posts are respectively set in the four management modules in advance;
step 2: the handheld terminal receives the path information issued by the server and performs routing inspection, maintenance or sampling according to the information;
and step 3: the handheld terminal scans the two-dimension code of the field operation point to obtain work information or requirements, starts operation according to the information or the requirements, and records and uploads routing inspection measurement data, equipment maintenance or sampling information and the like in the handheld terminal after the operation is finished;
and 4, step 4: if the work in the step 3 is process inspection or daily equipment inspection and basic maintenance, the following steps are required: 4.1 if the consistency of the measurement data recorded in the step 3 and the DCS remote transmission measurement data is within the allowable range, the handheld terminal and the server platform can mark that the work is finished after the measurement data is uploaded; 4.2 if the consistency is not within the allowable range, analyzing and processing the problem in the handheld terminal according to the prompt, after the processing is finished, clicking 'reset' in the polling display picture of the position number (two-dimensional code) in the handheld terminal and inputting the current measured value again; 4.3 if the problem found by the inspection point in 4.2 can not be solved in working (the condition that the outer operating post staff resets the corresponding inspection point in the handheld terminal is not satisfied), the inspection point is kept in a red state to be solved in the handheld terminal and the server platform, and when a new working list and a new route of the inspection of working in working are generated after the next outer operating post staff is in working, the inspection point in the red open state left in the previous working is placed at the first line of the list and the first station of the inspection line; 4.4 after the problem of the inspection point in the red state is solved, the staff at the post of the off-duty operation clicks the reset function of the hand-held wireless terminal and inputs a new measured value after the state is recovered, and the server platform records the final input value and the input time; 4.5 if the problem of the inspection point in the red state can not be solved in the second class, filling remark information (problem to be solved) into a red inspection parameter display card in the handheld equipment, and then selecting 'as a hidden danger troubleshooting finding item'; at the moment, the routing inspection parameter display is changed from red to yellow and marked as hidden danger, the hidden danger can be transmitted to a hidden danger troubleshooting and management system through a communication module of the server platform, and a corresponding hidden danger finding item is generated in the hidden danger; after the problem is finally solved, when the hidden danger inspection and treatment system closes the item, the states of the handheld equipment and the server platform about the inspection parameters are eliminated from yellow states, the hidden danger mark is canceled, the inspection bit number is changed into an inputtable state again, and the inspection point is reintroduced into a new round of arrangement plan of the inspection list;
and 5: if the work in step 3 is process sampling, the following steps are required: 5.1 the server platform stores the received sampling information data; the process sampling module exchanges data Information with an LIMS (laboratory Information Management System) through a communication module of the System to send newly obtained sample Information to the LIMS, and the LIMS can generate new corresponding sample analysis requirements in the System; 5.2 temporarily adding sample analysis requirements by a production team or additionally adding certain analysis item requirements for the existing sample analysis project, directly sending the analysis requirements to the LIMS system through a communication module of the system, and simultaneously directly pushing the work to a handheld terminal corresponding to an external operation post by using a 5G wireless signal;
step 6: the process parameters input by the external operator in the inspection process each time are recorded and stored in the inspection point position numbers corresponding to the server platform, after a period of time is accumulated, a historical trend record aiming at each process inspection point can be formed, and the promotion space and direction of the future stable operation of the control parameters are obtained through the analysis of the trend; KPI indexes such as inspection completion rate or inspection abnormal quantity of each inspection worker can be analyzed to obtain different conclusions of the working efficiency and effect of the external operation; and improving the overall level of the personnel in the outer operating posts through further standardization and training according to the conclusion.
7. A production activity supervision method for an external operation post of a chemical device is characterized by comprising the following steps:
step 1: the field operation supervision module acquires relevant information of all operation tickets of the current shift which are approved from an operation permission PTW (permit to work) system by utilizing a communication module of the system and generates an operation list of an area in charge of the external operation position;
step 2: when each production operation shift is handed over, the server platform pushes the operation list in the corresponding area to the handheld wireless intelligent terminal of the staff at each off-shift operation position; when the personnel at the external operating post are on site, the personnel carry out targeted inspection and supervision on the operation activities which are carried out on site according to the site operation information received by the handheld terminal; specifically, once an external operating post employee finds that the field operation has the phenomenon of non-compliance or danger, relevant violation or danger contents are filled in the operation page of the handheld terminal; after the operation party is required to be rectified and reformed, the operation is continued; stopping the field work for the operation which cannot be immediately rectified, and adjusting the operation state to be a 'shutdown rectification' yellow state at the handheld terminal; when the field construction operator informs the outside operating post staff that the rectification content is completed, the yellow state of 'shutdown rectification' is reset to the normal state after the on-site inspection and confirmation;
and step 3: after the server platform accumulates field operation information for a period of time, the server platform can be used for carrying out data and KPI analysis to find general problems and improve key points.
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